The power split plug-in hybrid electric bus (PHEB) boasts the capability for concurrent decoupling of rotation speed and torque, emerging as the key technology for energy conservation. The optimization of energy management strategies (EMSs) and powertrain parameters for PHEB contributes to bolstering vehicle performance and fuel economy. This paper revolves around optimizing fuel economy in PHEBs by proposing an optimization algorithm for the combination of a multi-layer rule-based energy management strategy (MRB-EMS) and powertrain parameters, with the former incorporating intelligent algorithms alongside deterministic rules. It commences by establishing a double-planetary-gear power split model for PHEBs, followed by parameter matching for powertrain components in adherence to relevant standards. Moving on, this paper plunges into the operational modes of the PHEB and assesses the system efficiency under each mode. The MRB-EMS is devised, with the battery’s State of Charge (SOC) serving as the hard constraint in the outer layer and the Charge Depletion and Charge Sustaining (CDCS) strategy forming the inner layer. To address the issue of suboptimal adaptive performance within the inner layer, an enhancement is introduced through the integration of optimization algorithms, culminating in the formulation of the enhanced MRB (MRB-II)-EMS. The fuel consumption of MRB-II-EMS and CDCS, under China City Bus Circle (CCBC) and synthetic driving cycle, decreased by 12.02% and 10.35% respectively, and the battery life loss decreased by 33.33% and 31.64%, with significant effects. Subsequent to this, a combined multi-layer powertrain optimization method based on Genetic Algorithm-Optimal Adaptive Control of Motor Efficiency-Particle Swarm Optimization (GOP) is proposed. In parallel with solving the optimal powertrain parameters, this method allows for the synchronous optimization of the Electric Driving (ED) mode and the Shutdown Charge Hold (SCH) mode within the MRB strategy. As evidenced by the results, the proposed optimization method is tailored for the EMSs and powertrain parameters. After optimization, fuel consumption was reduced by 9.04% and 18.11%, and battery life loss was decreased by 3.19% and 7.42% under the CCBC and synthetic driving cycle, which demonstrates a substantial elevation in the fuel economy and battery protection capabilities of PHEB.
